Printer with synchronized engine/controllers

ABSTRACT

A printer with synchronized engine/controllers is disclosed. The printer has a multi-segment printhead. Each engine/controller ( 10 ) configured to be coupled with others to drive the printhead ( 33 ). Each engine/controller ( 10 ) has an interface ( 27 ) at which to receive compressed page data. Image decoders ( 28, 88 ) decode compressed image planes image decoders to perform an expansion, in pipeline fashion, for the received compressed page data. A half-toner/compositor ( 29 ) composites respective strips of the decoded image planes and sends output to a printhead interface ( 32 ). A printhead interface ( 32 ) interfaces with the printhead. A synchronization signal generator ( 89, 90 ) may output a synchronization signal that is used to synchronize print engine/controllers. One printhead interface ( 32 ) preferably acts as master generating the synchronization signal to synchronize all the print engine/controllers to drive the printhead at any one or more of higher speed, higher input resolution, higher outlet resolution or wider format. The printhead interface comprises two LineSyncGen units, a first LineSyncGen unit providing a synchronization signal for multiple print engine/controller chips and a second LineSyncGen unit adapted to pulse a paper drive stepping motor.

CROSS REFERENCE TO RELATED APPLICATION

This is a Continuation Application of U.S. Ser. No. 09/607,985 filed onJun. 30, 2000, all of which is herein incorporated by reference.

FIELD OF THE INVENTION

The invention relates to a print engine/controller adapted to worktogether with a number of print engine/controllers in driving aprinthead and to a printhead driven by multiple printengine/controllers.

BACKGROUND OF THE INVENTION

In the prior art a single print engine/controller controls a singleprinthead. However this solution does not scale well for wider formatprintheads, for high resolution input images, or for faster printing.For wide format printheads the controller chip has to be made to runfaster in order to print the same number of printlines, each of which isnow longer. Or if the printhead is to run faster the print controllerhas to be run at a faster clock speed. Or if the input image has ahigher resolution then the controller chip has to have more buffersinternally or run faster or both in order to process the effectivelylarger input image since it is a higher resolution.

A range of printer types have evolved wherein an image is constructedfrom ink selectively applied to a page in dot format. In U.S. Pat. No.6,045,710 titled ‘Self-aligned construction and manufacturing processfor monolithic printheads’ to the inventor Kia Silverbrook there is setout an assessment of the prior art to drop on demand printers along withits manufacturing process.

Various methods, systems and apparatus relating to the present inventionare disclosed in the following co-pending United States patentapplications filed by the applicant or assignee of the present inventionon 23rd May 2000:

09/575,197, 09/575,195, 09/575,159, 09/575,132, 09/575,123, 09/575,148,09/575,130, 09/575,165, 09/575,153, 09/575,118, 09/575,131, 09/575,116,09/575,144, 09/575,139, 09/575,186, 09/575,185, 09/575,191, 09/575,145,09/575,192, 09/609,303, 09/610,095, 09/609,596, 09/575,181, 09/575,193,09/575,156, 09/575,183, 09/575,160, 09/575,150, 09/575,169, 09/575,184,6,502,614, 09/575,180, 09/575,149, 6,549,935, 09/575,187, 09/575,155,6,591,884, 6,439,706, 09/575,196, 09/575,198, 09/575,178, 6,428,155,09/575,146, 09/608,920, 09/575,174, 09/575,163, 09/575,168, 09/575,154,09/575,129, 09/575,124, 09/575,188, 09/575,189, 09/575,162, 09/575,172,09/575,170, 09/575,171, 09/575,161, 10/291,716, 6,428,133, 6,526,658,6,315,399, 6,338,548, 6,540,319, 6,328,431, 6,328,425, 09/575,127,6,383,833, 6,464,332, 6,439,693 6,390,591, 09/575,152, 6,328,417,6,409,323, 09/575,114, 6,604,810, 6,318,920, 6,488,422, 09/575,108,09/575,109 09/575,110.

In addition, various methods, systems and apparatus relating to thepresent invention are disclosed in the following co-pending UnitedStates patent applications filed simultaneously by the applicant orassignee of the present invention: U.S. Pat. Nos. 6,398,332, 6,394,573,6,622,923.

The disclosures of these co-pending applications are incorporated hereinby cross-reference. Each application is temporarily identified by itsdocket number. This will be replaced by the corresponding U.S. Ser. No.when available.

Of particular note are co-pending U.S. patent applications Ser. No.09/575,152, U.S. Pat. Nos. 6,428,133, 6,526,658, 6,328,417, 6,390,591,which describe a microelectomechanical drop on demand printheadhereafter referred to as a Memjet printhead.

The Memjet printhead is developed from printhead segments that arecapable of producing, for example, 1600 dpi bi-level dots of liquid inkacross the full width of a page. Dots are easily produced in isolation,allowing dispersed-dot dithering to be exploited to its fullest. Colorplanes might be printed in perfect registration, allowing idealdot-on-dot printing. The printhead enables high-speed printing usingmicroelectromechanical ink drop technology.

In addition, co-pending U.S. patent applications Ser. Nos. 09/575,108,09/575,109, 09/575,110 U.S. Pat. No. 6,398,332, 6,394,573, 6,622,923describe a print engine/controller suited to driving the abovereferenced page wide printhead.

A single print engine/controller (PEC) chip is capable of driving aprinthead of the above referenced type, printing a dithered version of a320 ppi contone image over a 12 inch printhead. It is desirable to beable to print higher resolution images for higher quality output. It isdesirable to be able to run the printhead faster.

SUMMARY OF THE INVENTION

The invention resides in a print engine/controller configured to becoupled with others to drive an ink drop printhead comprising:

an interface at which to receive compressed page data;

image decoders to decode compressed image planes in the receivedcompressed page data;

-   -   a half-toner/compositer to composite respective strips of the        decoded image planes; and    -   a printhead interface to output the composite strip to a        printhead the printhead interface including:        -   a multi-segment printhead interface outputting printhead            formatted data; and        -   a synchronization signal generator outputting a            synchronization signal to couple print engine/controllers to            synchronize their respective strips at the printhead.

A Memjet printhead is a multi-segment printhead, where each segment ofthe printhead has physical connections. For example Memjet printheadscan be constructed from multiple chips, each of which contains a singleprinthead segment, or can be constructed from multiple chips each ofwhich contains more than one segment. The wiring is the same in bothcases, and the logical connectivity is the same in both cases—multiplesegments combining to form a wider printhead.

The present invention advantageously uses multiple copies of the sameprint engine controller chip to drive a multi-segment printhead, eachresponsible for a strip of the page, all synchronized from a masterchip. A variety of configurations can be built depending on the requiredapplication. For example, given a 12-segment printhead, a single printengine/controller (PEC) can be used to run the entire printhead at acontone resolution of 320 ppi and at a maximum line speed of 30,000lines per second. If double speed is to be achieved, 2 PECs can control6 segments each, still running at 320 ppi contone resolution. But theeffective speed has been doubled. Similarly, if the contone resolutionis to be pushed to 640 ppi, 2 PECs can run the printhead at 30,000 linesper second.

Synchronization can also be readily used for simultaneous duplexprinting. One PEC prints 12 inches (15 segments) on one side of a page,while a second PEC simultaneously prints the second side of the page. Aslong as there is a single Master PEC chip giving the synchronizationsignals, combinations of PECs can be achieved.

Driving a single printhead from multiple chips is advantageous toproduce wider pages, faster prints, higher input resolution, orcombinations of all three.

To use multiple PECs, the same page can be given to multiple PECs.Different PECs then deal with strips of the page data, producing thetotal page in a faster time and/or higher resolution. A simple way ofsending data to the printhead from multiple PECs is simply to have eachPEC responsible for a given number of printhead segments.

The programming of individual PECs for strips within the overall page isorganized in a margin unit within a half-toner/compositer within eachPEC. A tag encoder within each print engine/controller is able to dealwith a strip of a page and is capable of producing a partial tag whentagged pages are desirable.

When several PECs are used in unison, such as in a duplexedconfiguration or in a printhead configuration that consists of more than15 Memjet segments, they are synchronized via a shared line sync signal.Only one Printhead Controller Chip, selected via an externalmaster/slave pin, generates the line sync signal onto the shared line.The internals of PEC allow for printing a single strip of a page inconjunction with other PECs. This includes generation of partial Netpagetags and page descriptions. However it is up to the external pageprovider to allocate the various strips to each PEC correctly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagram illustrating data flow and the functions performedby the print engine controller.

FIG. 2 shows the print engine controller in the context of the overallprinter system architecture.

FIG. 3 illustrates the print engine controller architecture.

FIG. 4 illustrates the external interfaces to the halftoner/compositorunit (HCU) of FIG. 3.

FIG. 5 is a diagram showing internal circuitry to the HCU of FIG. 4.

FIG. 6 shows a block diagram illustrating the process within the dotmerger unit of FIG. 5.

FIG. 7 shows a diagram illustrating the process within the dotreorganization unit of FIG. 5.

FIG. 8 shows a diagram illustrating the process within the lineloader/format unit (LLFU) of FIG. 5.

FIG. 9 is a diagram showing internal circuitry to generate color data inthe LLFU of FIG. 8.

FIGS. 10 and 11 illustrate components of the LLFU seen in FIG. 9.

FIG. 12 is a diagram showing internal circuitry to a printheadinterface.

FIG. 13 is a diagram of a dot counter used in the printhead interface.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

A typically 12 inch printhead width is controlled by one or more printengine/controllers (PECs), as described below, to allow full-bleedprinting of both A4 and Letter pages. Six channels of colored ink arethe expected maximum in the present printing environment, these being:

-   CMY, for regular color printing.-   K, for black text and other black printing.-   IR (infrared), for tag-enabled applications.-   F (fixative), to enable printing at high speed.

Because the printer is to be capable of fast printing, a fixative willbe required to enable the ink to dry before the next page has completedprinting at higher speeds. Otherwise the pages might bleed on eachother. In lower speed printing environments the fixative will not berequired.

A PEC might be built in a single chip to interface with a printhead. Itwill contain four basic levels of functionality:

-   receiving compressed pages via a serial interface such as IEEE 1394-   a print engine for producing a page from a compressed form. The    print engine functionality includes expanding the page image,    dithering the contone layer, compositing the black layer over the    contone layer, optionally adding infrared tags, and sending the    resultant image to the printhead.-   a print controller for controlling the printhead and stepper motors.-   two standard low-speed serial ports for communication with the two    QA chips. Note that there must be two ports and not a single port to    ensure strong security during the authentication procedure.

In FIG. 1 is seen the flow of data to send a document from computersystem to printed page. A document is received at 11 and loaded tomemory buffer 12 wherein page layouts may be effected and any requiredobjects might be added. Pages from memory 12 are rasterized at 13 andcompressed at 14 prior to transmission to the print engine controller10. Pages are received as compressed page images within the print enginecontroller 10 into a memory buffer 15, from which they are fed to a pageexpander 16 wherein page images are retrieved. Any requisite dithermight be applied to any contone layer at 17. Any black bi-level layermight be composited over the contone layer at 18 together with anyinfrared tags at 19. The composited page data is printed at 20 toproduce page 21.

The print engine/controller takes the compressed page image and startsthe page expansion and printing in pipeline fashion. Page expansion andprinting is preferably pipelined because it is impractical to store asizable bi-level CMYK+IR page image in memory.

The first stage of the pipeline expands a JPEG-compressed contone CMYKlayer (see below), expands a Group 4 Fax-compressed bi-level dithermatrix selection map (see below), and expands a Group 4 Fax-compressedbi-level black layer (see below), all in parallel. In parallel withthis, the tag encoder encodes bi-level IR tag data from the compressedpage image. The second stage dithers the contone CMYK layer using adither matrix selected by the dither matrix select map, composites thebi-level black layer over the resulting bi-level K layer and adds the IRlayer to the page. A fixative layer is also generated at each dotposition wherever there is a need in any of C, M, Y, K, or IR channels.The last stage prints the bi-level CMYK+IR data through the printheadvia a printhead interface (see below).

In FIG. 2 is seen how the print engine/controller 10 fits within theoverall printer system architecture. The various components of theprinter system might include

-   a Print Engine/Controller (PEC). A PEC chip 10, or chips, is    responsible for receiving the compressed page images for storage in    a memory buffer 24, performing the page expansion, black layer    compositing and sending the dot data to the printhead 23. It may    also communicate with QA chips 25,26 and provides a means of    retrieving printhead characteristics to ensure optimum printing. The    PEC is the subject of this specification.-   a memory buffer. The memory buffer 24 is for storing the compressed    page image and for scratch use during the printing of a given page.    The construction and working of memory buffers is known to those    skilled in the art and a range of standard chips and techniques for    their use might be utilized in use of the PEC of the invention.-   a master QA chip. The master chip 25 is matched to replaceable ink    cartridge QA chips 26. The construction and working of QA units is    known to those skilled in the art and a range of known QA processes    might be utilized in use of the PEC of the invention. For example, a    QA chip is described in co-pending U.S. patent applications:

Our docket USSN number Our Title TBA AUTH01 Validation Protocol andSystem 09/112,763 AUTH02 Circuit for Protecting Chips Against IDDFluctuation Attacks 09/112,737 AUTH04 Method for Protecting On-ChipMemory (Flash and RAM) 09/112,761 AUTH05 Method for Making a ChipTamper-Resistant 09/113,223 AUTH06 A system for authenticating physicalobjects TBA AUTH07 Validation Protocol and System TBA AUTH08 ValidationProtocol and System 09/505,003 AUTH09 Consumable Authentication Protocoland System 09/517,608 AUTH10 Consumable Authentication Protocol andSystem 09/505,147 AUTH11 Consumable Authentication Protocol and System09/505,952 AUTH12 Unauthorized Modification of Values Stored in FlashMemory TBA AUTH13 A System for the Manipulation of Secure Data09/516,874 AUTH14 An Authentication Chip with Protection from PowerSupply Attacks TBA AUTH15 Shielding Manipulations of Secret Data

QA chip communication may be best included within the overallfunctionality of the PEC chip since it has a role in the expansion ofthe image as well as running the physical printhead. By locating QA chipcommunication there it can be ensured that there is enough ink to printthe page. Preferably the QA embedded in the printhead assembly isimplemented using an authentication chip. Since it is a master QA chip,it only contains authentication keys, and does not contain user-data.However, it must match the ink cartridge's QA chip. The QA chip in theink cartridge contains information required for maintaining the bestpossible print quality, and is implemented using an authentication chip.

Preferably a 64 MBit (8 MByte) memory buffer is used to store thecompressed page image. While one page is being written to the bufferanother is being read (double buffering). In addition, the PEC uses thememory to buffer the calculated dot information during the printing of apage. During the printing of page N, the buffer is used for:

-   Reading compressed page N-   Reading and writing the bi-level dot information for page N-   Writing compressed page N+1

Preferably a PEC chip will incorporate a simple micro-controller CPUcore 35 to perform the following functions:

-   perform QA chip authentication protocols via serial interface 36    between print pages-   run the stepper motor via a parallel interface 91 during a print    (the stepper motor requires a 5 kHz process)-   synchronize the various portions of the PEC chip during a print-   provide a means of interfacing with external data requests    (programming registers etc.)-   provide a means of interfacing with printhead segment low-speed data    requests (such as reading the characterization vectors and writing    pulse profiles)-   provide a means of writing the portrait and landscape tag structures    to external DRAM

Since all of the image processing is performed by dedicated hardware,the CPU does not have to process pixels. As a result, the CPU can beextremely simple. A wide variety of CPU known cores are suitable: it canbe any processor core with sufficient processing power to perform therequired calculations and control functions fast enough. An example of asuitable core is a Philips 8051 micro-controller running at about 1 MHz.Associated with the CPU core 35 may be a program ROM and a small programscratch RAM. The CPU communicates with the other units within the PECchip via memory-mapped I/O. Particular address ranges may map toparticular units, and within each range, to particular registers withinthat particular unit. This includes the serial 36 and parallel 91interfaces. A small program flash ROM may be incorporated into the PECchip. Its size depends on the CPU chosen, but should not be more than 8KB. Likewise, a small scratch RAM area can be incorporated into the PECchip. Since the program code does not have to manipulate images, thereis no need for a large scratch area. The RAM size depends on the CPUchosen (e.g. stack mechanisms, subroutine calling conventions, registersizes etc.), but should not be more than about 2 KB.

A PEC chip using the above referenced segment based page wide printheadcan reproduce black at a full dot resolution (typically 1600 dpi), butreproduces contone color at a somewhat lower resolution usinghalftoning. The page description is therefore divided into a blackbi-level layer and a contone layer. The black bi-level layer is definedto composite over the contone layer. The black bi-level layer consistsof a bitmap containing a 1-bit opacity for each pixel. This black layermatte has a resolution that is an integer factor of the printer's dotresolution. The highest supported resolution is 1600 dpi, i.e. theprinter's full dot resolution. The contone layer consists of a bitmapcontaining a 32-bit CMYK color for each pixel, where K is optional. Thiscontone image has a resolution that is an integer factor of theprinter's dot resolution. The highest supported resolution is 320 ppiover 12 inches for a single PEC, i.e. one-fifth the printer's dotresolution. For higher contone resolutions multiple PECs are required,with each PEC producing an strip of the output page. The contoneresolution is also typically an integer factor of the black bi-levelresolution, to simplify calculations in the RIPs. This is not arequirement, however. The black bi-level layer and the contone layer areboth in compressed form for efficient storage in the printer's internalmemory.

In FIG. 3 is seen the print engine architecture. The print engine's pageexpansion and printing pipeline consists of a high speed serialinterface 27 (such as a standard IEEE 1394 interface), a standard JPEGdecoder 28, a standard Group 4 Fax decoder, a customhalftoner/compositor unit 29, a custom tag encoder 30, a lineloader/formatter unit 31, and a custom interface 32 to the printhead 33.The decoders 28,88 and encoder 30 are buffered to thehalftoner/compositor 29. The tag encoder 30 establishes an infrared tagor tags to a page according to protocols dependent on what uses might bemade of the page and the actual content of a tag is not the subject ofthe present invention.

The print engine works in a double buffered way. One page is loaded intoDRAM 34 via DRAM interface 89 and data bus 90 from the high speed serialinterface 27 while the previously loaded page is read from DRAM 34 andpassed through the print engine pipeline. Once the page has finishedprinting, then the page just loaded becomes the page being printed, anda new page is loaded via the high-speed serial interface 27. At thefirst stage the pipeline expands any JPEG-compressed contone (CMYK)layer, and expands any of two Group 4 Fax-compressed bi-level datastreams. The two streams are the black layer (although the PEC isactually color agnostic and this bi-level layer can be directed to anyof the output inks), and a matte for selecting between dither matricesfor contone dithering (see below). At the second stage, in parallel withthe first, is encoded any tags for later rendering in either IR or blackink. Finally the third stage dithers the contone layer, and compositesposition tags and the bi-level spot1 layer over the resulting bi-leveldithered layer. The data stream is ideally adjusted to create smoothtransitions across overlapping segments in the printhead and ideally itis adjusted to compensate for dead nozzles in the printhead. Up to 6channels of bi-level data are produced from this stage. Note that notall 6 channels may be present on the printhead. For example, theprinthead may be CMY only, with K pushed into the CMY channels and IRignored. Alternatively, the position tags may be printed in K if IR inkis not available (or for testing purposes). The resultant bi-levelCMYK−IR dot-data is buffered and formatted for printing on the printhead33 via a set of line buffers (see below). The majority of these linebuffers might be ideally stored on the off-chip DRAM 34. The final stageprints the 6 channels of bi-level dot data via the printhead interface32.

Compression is used in a printing system that employs the PEC. This isto reduce bandwidth requirements between a host and PEC, as well as toreduce memory requirements for page storage. At 267 ppi, a Letter pageof contone CMYK data has a size of 25 MB. Using lossy contonecompression algorithms such as JPEG (see below), contone images compresswith a ratio up to 10:1 without noticeable loss of quality, giving acompressed page size of 2.5 MB. At 800 dpi, a Letter page of bi-leveldata has a size of 7 MB. Coherent data such as text compresses verywell. Using lossless bi-level compression algorithms such as Group 4Facsimile (see below), ten-point text compresses with a ratio of about10:1, giving a compressed page size of 0.8 MB. Once dithered, a page ofCMYK contone image data consists of 114 MB of bi-level data. Thetwo-layer compressed page image format described below exploits therelative strengths of lossy JPEG contone image compression and losslessbi-level text compression. The format is compact enough to bestorage-efficient, and simple enough to allow straightforward real-timeexpansion during printing. Since text and images normally don't overlap,the normal worst-case page image size is 2.5 MB (i.e. image only), whilethe normal best-case page image size is 0.8 MB (i.e. text only). Theabsolute worst-case page image size is 3.3 MB (i.e. text over image).Assuming a quarter of an average page contains images, the average pageimage size is 1.2 MB.

A Group 3 Facsimile compression algorithm (see ANSI/EIA 538–1988,Facsimile Coding Schemes and Coding Control Functions for Group 4Facsimile Equipment, August 1988) can be used to losslessly compressesbi-level data for transmission over slow and noisy telephone lines. Thebi-level data represents scanned black text and graphics on a whitebackground, and the algorithm is tuned for this class of images (it isexplicitly not tuned, for example, for halftoned bi-level images). TheID Group 3 algorithm runlength-encodes each scanline and thenHuffman-encodes the resulting runlengths. Runlengths in the range 0 to63 are coded with terminating codes. Runlengths in the range 64 to 2623are coded with make-up codes, each representing a multiple of 64,followed by a terminating code. Runlengths exceeding 2623 are coded withmultiple make-up codes followed by a terminating code. The Huffmantables are fixed, but are separately tuned for black and white runs(except for make-up codes above 1728, which are common). When possible,the 2D Group 3 algorithm encodes a scanline as a set of short edgedeltas (0, ±1, ±2, ±3) with reference to the previous scanline. Thedelta symbols are entropy-encoded (so that the zero delta symbol is onlyone bit long etc.) Edges within a 2D-encoded line that can't bedelta-encoded are runlength-encoded, and are identified by a prefix. 1D-and 2D-encoded lines are marked differently. ID-encoded lines aregenerated at regular intervals, whether actually required or not, toensure that the decoder can recover from line noise with minimal imagedegradation. 2D Group 3 achieves compression ratios of up to 6:1 (seeUrban, S. J., “Review of standards for electronic imaging for facsimilesystems”, Journal of Electronic Imaging, Vol.1(1), January 1992,pp.5–21).

A Group 4 Facsimile algorithm (see ANSI/EIA 538–1988, Facsimile CodingSchemes and Coding Control Functions for Group 4 Facsimile Equipment,August 1988) losslessly compresses bi-level data for transmission overerror-free communications lines (i.e. the lines are truly error-free, orerror-correction is done at a lower protocol level). The Group 4algorithm is based on the 2D Group 3 algorithm, with the essentialmodification that since transmission is assumed to be error-free,1D-encoded lines are no longer generated at regular intervals as an aidto error-recovery. Group 4 achieves compression ratios ranging from 20:1to 60:1 for the CCITT set of test images. The design goals andperformance of the Group 4 compression algorithm qualify it as acompression algorithm for the bi-level layers. However, its Huffmantables are tuned to a lower scanning resolution (100–400 dpi), and itencodes runlengths exceeding 2623 awkwardly.

At 800 dpi, our maximum runlength is currently 6400. Although a Group 4decoder core would be available for use in PEC, it might not handlerunlengths exceeding those normally encountered in 400 dpi facsimileapplications, and so would require modification. The (typically 1600dpi) black layer is losslessly compressed using G4 Fax at a typicalcompression ratio exceeding 10:1. A (typically 320 dpi) dither matrixselect layer, which matches the contone color layer, is losslesslycompressed using G4 Fax at a typical compression ratio exceeding 50:1.

The Group 4 Fax (G4 Fax) decoder is responsible for decompressingbi-level data. Bi-level data is limited to a single spot color(typically black for text and line graphics), and a dither matrix selectbit-map for use in subsequent dithering of the contone data(decompressed by the JPEG decoder). The input to the G4 Fax decoder is 2planes of bi-level data, read from the external DRAM. The output of theG4 Fax decoder is 2 planes of decompressed bi-level data. Thedecompressed bi-level data is sent to the Halftoner/Compositor Unit(HCU) for the next stage in the printing pipeline. Two bi-level buffersprovides the means for transferring the bi-level data between the G4 Faxdecoder and the HCU. Each decompressed bi-level layer is output to twoline buffers. Each buffer is capable of holding a full 12 inch line ofdots at the expected maximum resolution. Having two line buffers allowsone line to be read by the HCU while the other line is being written toby the G4 Fax decoder. This is important because a single bi-level lineis typically less than 1600 dpi, and must therefore be expanded in boththe dot and line dimensions. If the buffering were less than a fullline, the G4 Fax decoder would have to decode the same line multipletimes—once for each output 600 dpi dotline.

Spot color 1 is designed to allow high resolution dot data for a singlecolor plane of the output image. While the contone layers provideadequate resolution for images, spot color 1 is targeted at applicationssuch as text and line graphics (typically black). When used as text andline graphics, the typical compression ratio exceeds 10:1. Spot color 1allows variable resolution up to 1600 dpi for maximum print quality.Each of the two line buffers is therefore total 2400 bytes (12inches×1600 dpi=19,200 bits).

The resolution of the dither matrix select map should ideally match thecontone resolution. Consequently each of the two line buffers istherefore 480 bytes (3840 bits), capable of storing 12 inches at 320dpi. When the map matches the contone resolution, the typicalcompression ratio exceeds 50:1.

In order to provide support for:

-   800 dpi spot color 1 layer (typically black)-   320 dpi dither matrix select layer the decompression bandwidth    requirements are 9.05 MB/sec for 1 page per second performance    (regardless of whether the page width is 12 inches or 8.5 inches),    and 20 MB/sec and 14.2 MB/sec for 12 inch and 8.5 inch page widths    respectively during maximum printer speed performance (30,000 lines    per second). Given that the decompressed data is output to a line    buffer, the G4 Fax decoder can readily decompress a line from each    of the outputs one at a time.

The G4 Fax decoder is fed directly from the main memory via the DRAMinterface. The amount of compression determines the bandwidthrequirements to the external DRAM. Since G4 Fax is lossless, thecomplexity of the image impacts on the amount of data and hence thebandwidth. typically an 800 dpi black text/graphics layer exceeds 10:1compression, so the bandwidth required to print 1 page per second is0.78 MB/sec. Similarly, a typical 320 dpi dither select matrixcompresses at more than 50:1, resulting in a 0.025 MB/sec bandwidth. Thefastest printing speed configuration of 320 dpi for dither select matrixand 800 dpi for spot color 1 requires bandwidth of 1.72 MB/sec and 0.056MB/sec respectively. A total bandwidth of 2 MB/sec should therefore bemore than enough for the DRAM bandwidth.

The G4 Fax decoding functionality is implemented by means of a G4 FaxDecoder core. A wide variety of G4 Fax Decoder cores are suitable: itcan be any core with sufficient processing power to perform the requiredcalculations and control functions fast enough. It must be capable ofhandling runlengths exceeding those normally encountered in 400 dpifacsimile applications, and so may require modification.

A JPEG compression algorithm (see ISO/IEC 19018–1:1994, Informationtechnology—Digital compression and coding of continuous-tone stillimages: Requirements and guidelines, 1994) lossily compresses a contoneimage at a specified quality level. It introduces imperceptible imagedegradation at compression ratios below 5:1, and negligible imagedegradation at compression ratios below 10:1 (see Wallace, G. K., “TheJPEG Still Picture Compression Standard”, Communications of the ACM,Vol.34, No.4, April 1991, pp.30–44). JPEG typically first transforms theimage into a color space that separates luminance and chrominance intoseparate color channels. This allows the chrominance channels to besub-sampled without appreciable loss because of the human visualsystem's relatively greater sensitivity to luminance than chrominance.After this first step, each color channel is compressed separately. Theimage is divided into 8×8 pixel blocks. Each block is then transformedinto the frequency domain via a discrete cosine transform (DCT). Thistransformation has the effect of concentrating image energy inrelatively lower-frequency coefficients, which allows higher-frequencycoefficients to be more crudely quantized. This quantization is theprincipal source of compression in JPEG. Further compression is achievedby ordering coefficients by frequency to maximize the likelihood ofadjacent zero coefficients, and then runlength-encoding runs of zeroes.Finally, the runlengths and non-zero frequency coefficients are entropycoded. Decompression is the inverse process of compression.

The CMYK (or CMY) contone layer is compressed to a planar color JPEGbytestream. If luminance/chrominance separation is deemed necessary,either for the purposes of table sharing or for chrominancesub-sampling, then CMYK is converted to YCrCb and Cr and Cb are dulysub-sampled. The JPEG bytestream is complete and self-contained. Itcontains all data required for decompression, including quantization andHuffman tables.

The JPEG decoder is responsible for performing the on-the-flydecompression of the contone data layer. The input to the JPEG decoderis up to 4 planes of contone data. This will typically be 3 planes,representing a CMY contone image, or 4 planes representing a CMYKcontone image. Each color plane can be in a different resolution,although typically all color planes will be the same resolution. Thecontone layers are read from the external DRAM. The output of the JPEGdecoder is the decompressed contone data, separated into planes. Thedecompressed contone image is sent to the halftoner/compositor unit(HCU) 29 for the next stage in the printing pipeline. The 4-planecontone buffer provides the means for transferring the contone databetween the JPEG decoder and the HCU 29.

Each color plane of the decompressed contone data is output to a set oftwo line buffers (see below). Each line buffer is 3840 bytes, and istherefore capable of holding 12 inches of a single color plane's pixelsat 320 ppi. The line buffering allows one line buffer to be read by theHCU while the other line buffer is being written to by the JPEG decoder.This is important because a single contone line is typically less than1600 ppi, and must therefore be expanded in both the dot and linedimensions. If the buffering were less than a full line, the JPEGdecoder would have to decode the same line multiple times—once for eachoutput 600 dpi dotline. Although a variety of resolutions is supported,there is a tradeoff between the resolution and available bandwidth. Asresolution and number of colors increase, bandwidth requirements alsoincrease. In addition, the number of segments being targeted by the PECchip also affects the bandwidth and possible resolutions. Note thatsince the contone image is processed in a planar format, each colorplane can be stored at a different resolution (for example CMY may be ahigher resolution than the K plane). The highest supported contoneresolution is 1600 ppi (matching the printer's full dot resolution).However there is only enough output line buffer memory to hold enoughcontone pixels for a 320 ppi line of length 12 inches. If the full 12inches of output was required at higher contone resolution, multiple PECchips would be required, although it should be noted that the finaloutput on the printer will still only be bi-level. With support for 4colors at 320 ppi, the decompression output bandwidth requirements are40 MB/sec for 1 page per second performance (regardless of whether thepage width is 12 inches or 8.5 inches), and 88 MB/sec and 64 MB/sec for12 inch and 8.5 inch page widths respectively during maximum printerspeed performance (30,000 lines per second).

The JPEG decoder is fed directly from the main memory via the DRAMinterface. The amount of compression determines the bandwidthrequirements to the external DRAM. As the level of compressionincreases, the bandwidth decreases, but the quality of the final outputimage can also decrease. The DRAM bandwidth for a single color plane canbe readily calculated by applying the compression factor to the outputbandwidth. For example, a single color plane at 320 ppi with acompression factor of 10:1 requires 1 MB/sec access to DRAM to produce asingle page per second.

The JPEG functionality is implemented by means of a JPEG core. A widevariety of JPEG cores are suitable: it can be any JPEG core withsufficient processing power to perform the required calculations andcontrol functions fast enough. For example, the BTG X-Match core hasdecompression speeds up to 140 MBytes/sec, which allows decompression of4 color planes at contone resolutions up to 400 ppi for the maximumprinter speed (30,000 lines at 1600 dpi per second), and 800 ppi for 1page/sec printer speed. Note that the core needs to only supportdecompression, reducing the requirements that are imposed by moregeneralized JPEG compression/decompression cores. The size of the coreis expected to be no more than 100,000 gates. Given that thedecompressed data is output to a line buffer, the JPEG decoder canreadily decompress an entire line for each of the color planes one at atime, thus saving on context switching during a line and simplifying thecontrol of the JPEG decoder. 4 contexts must be kept (1 context for eachcolor plane), and includes current address in the external DRAM as wellas appropriate JPEG decoding parameters.

In FIG. 4 the halftoner/compositor unit (HCU) 29 combines the functionsof halftoning the contone (typically CMYK) layer to a bi-level versionof the same, and compositing the spot1 bi-level layer over theappropriate halftoned contone layer(s). If there is no K ink in theprinter, the HCU 29 is able to map K to CMY dots as appropriate. It alsoselects between two dither matrices on a pixel by pixel basis, based onthe corresponding value in the dither matrix select map. The input tothe HCU 29 is an expanded contone layer (from the JPEG decoder unit)through buffer 37, an expanded bi-level spot1 layer through buffer 38,an expanded dither-matrix-select bitmap at typically the same resolutionas the contone layer through buffer 39, and tag data at full dotresolution through buffer 40. The HCU 29 uses up to two dither matrices,read from the external DRAM 34. The output from the HCU 29 to the lineloader/format unit (LLFU) at 41 is a set of printer resolution bi-levelimage lines in up to 6 color planes. Typically, the contone layer isCMYK or CMY, and the bi-level spot1 layer is K.

In FIG. 5 is seen the HCU in greater detail. Once started, the HCUproceeds until it detects an end-of-page condition, or until it isexplicitly stopped via its control register. The first task of the HCUis to scale, in the respective scale units such as the scale unit 43,all data, received in the buffer planes such as 42, to printerresolution both horizontally and vertically.

The scale unit provides a means of scaling contone or bi-level data toprinter resolution both horizontally and vertically. Scaling is achievedby replicating a data value an integer number of times in bothdimensions. Processes by which to scale data will be familiar to thoseskilled in the art.

Two control bits are provided to the scale unit 43 by the margin unit57: advance dot and advance line. The advance dot bit allows the statemachine to generate multiple instances of the same dot data (useful forpage margins and creating dot data for overlapping segments in theprinthead). The advance line bit allows the state machine to controlwhen a particular line of dots has been finished, thereby allowingtruncation of data according to printer margins. It also saves the scaleunit from requiring special end-of-line logic. The input to the scaleunit is a full line buffer. The line is used scale factor times toeffect vertical up-scaling via line replication, and within each line,each value is used scale factor times to effect horizontal up-scalingvia pixel replication. Once the input line has been used scale factortimes (the advance line bit has been set scale factor times), the inputbuffer select bit of the address is toggled (double buffering). Thelogic for the scale unit is the same for the 8-bit and 1-bit case, sincethe scale unit only generates addresses.

Since each of the contone layers can be a different resolution, they arescaled independently. The bi-level spot1 layer at buffer 45 and thedither matrix select layer at buffer 46 also need to be scaled. Thebi-level tag data at buffer 47 is established at the correct resolutionand does not need to be scaled. The scaled-up dither matrix select bitis used by the dither matrix access unit 48 to select a single 8-bitvalue from the two dither matrices. The 8-bit value is output to the 4comparators 44, and 49 to 51, which simply compare it to the specific8-bit contone value. The generation of an actual dither matrix isdependent on the structure of the printhead and the general processes bywhich to generate one will be familiar to those skilled in the art. Ifthe contone value is greater than the 8-bit dither matrix value a 1 isoutput. If not, then a 0 is output. These bits are then all ANDed at 52to 56 with an inPage bit from the margin unit 57 (whether or not theparticular dot is inside the printable area of the page). The finalstage in the HCU is the compositing stage. For each of the 6 outputlayers there is a single dot merger unit, such as unit 58, each with 6inputs. The single output bit from each dot merger unit is a combinationof any or all of the input bits. This allows the spot color to be placedin any output color plane (including infrared for testing purposes),black to be merged into cyan, magenta and yellow (if no black ink ispresent in the printhead), and tag dot data to be placed in a visibleplane. A fixative color plane can also be readily generated. The dotreorg unit (DRU) 59 is responsible for taking the generated dot streamfor a given color plane and organizing it into 32-bit quantities so thatthe output is in segment order, and in dot order within segments.Minimal reordering is required due to the fact that dots for overlappingsegments are not generated in segment order.

Two control bits are provided to the scale units by the margin unit 57:advance dot and advance line. The advance dot bit allows the statemachine to generate multiple instances of the same dot data (useful forpage margins and creating dot data for overlapping segments in theprinthead). The advance line bit allows the state machine to controlwhen a particular line of dots has been finished, thereby allowingtruncation of data according to printer margins. It also saves the scaleunit from requiring special end-of-line logic.

The comparator unit contains a simple 8-bit “greater-than” comparator.It is used to determine whether the 8-bit contone value is greater thanthe 8-bit dither matrix value. As such, the comparator unit takes two8-bit inputs and produces a single 1-bit output.

In FIG. 6 is seen more detail of the dot merger unit. It provides ameans of mapping the bi-level dithered data, the spot1 color, and thetag data to output inks in the actual printhead. Each dot merger unittakes 6 1-bit inputs and produces a single bit output that representsthe output dot for that color plane. The output bit at 60 is acombination of any or all of the input bits. This allows the spot colorto be placed in any output color plane (including infrared for testingpurposes), black to be merged into cyan, magenta and yellow (in the caseof no black ink in the printhead), and tag dot data to be placed in avisible plane. An output for fixative can readily be generated by simplycombining all of the input bits. The dot merger unit contains a 6-bitColorMask register 61 that is used as a mask against the 6 input bits.Each of the input bits is ANDed with the corresponding ColorMaskregister bit, and the resultant 6 bits are then ORed together to formthe final output bit.

In FIG. 7 is seen the dot reorg unit (DRU) which is responsible fortaking the generated dot stream for a given color plane and organizingit into 32-bit quantities so that the output is in segment order, and indot order within segments. Minimal reordering is required due to thefact that dots for overlapping segments are not generated in segmentorder. The DRU contains a 32-bit shift register, a regular 32-bitregister, and a regular 16-bit register. A 5-bit counter keeps track ofthe number of bits processed so far. The dot advance signal from thedither matrix access unit (DMAU) is used to instruct the DRU as to whichbits should be output.

In FIG. 7 register(A) 62 is clocked every cycle. It contains the 32 mostrecent dots produced by the dot merger unit (DMU). The full 32-bit valueis copied to register(B) 63 every 32 cycles by means of a WriteEnablesignal produced by the DRU state machine 64 via a simple 5-bit counter.The 16 odd bits (bits 1, 3, 5, 7 etc.) from register(B) 63 are copied toregister(C) 65 with the same WriteEnable pulse. A 32-bit multiplexor 66then selects between the following 3 outputs based upon 2 bits from thestate machine:

-   the full 32 bits from register B-   A 32-bit value made up from the 16 even bits of register A (bits 0,    2, 4, 6 etc.) and the 16 even bits of register B. The 16 even bits    from register A form bits 0 to 15, while the 16 even bits from    register B form bits 16–31.-   A 32-bit value made up from the 16 odd bits of register B (bits 1,    3, 5, 7 etc.) and the 16 bits of register C. The bits of register C    form bits 0 to 15, while the odd bits from register B form bits    16–13.

The state machine for the DRU can be seen in Table 1. It starts in state0. It changes state every 32 cycles. During the 32 cycles a singlenoOverlap bit collects the AND of all the dot advance bits for those 32cycles (noOverlap=dot advance for cycle 0, and noOverlap=noOverlap ANDdot advance for cycles 1 to 31).

TABLE 1 State machine for DRU output state NoOverlap Output ValidComment next state 0 X B 0 Startup state 1 1 1 B 1 Regular non- 1overlap 1 0 B 1 A contains first 2 overlap 2 X Even A, 1 A containssecond 3 even B overlap B contains first overlap 3 X C, odd B 1 Ccontains first 1 overlap B contains second overlap

The margin unit (MU) 57, in FIG. 5, is responsible for turning advancedot and advance line signals from the dither matrix access unit (DMAU)48 into general control signals based on the page margins of the currentpage. It is also responsible for generating the end of page condition.The MU keeps a counter of dot and line across the page. Both are set to0 at the beginning of the page. The dot counter is advanced by 1 eachtime the MU receives a dot advance signal from the DMAU. When the MUreceives a line advance signal from the DMAU, the line counter isincremented and the dot counter is reset to 0. Each cycle, the currentline and dot values are compared to the margins of the page, andappropriate output dot advance, line advance and within margin signalsare given based on these margins. The DMAU contains the only substantialmemory requirements for the HCU.

In FIG. 8 is seen the line loader/format unit (LLFU). It receives dotinformation from the HCU, loads the dots for a given print line intoappropriate buffer storage (some on chip, and some in external DRAM 34)and formats them into the order required for the printhead. A high levelblock diagram of the LLFU in terms of its external interface is shown inFIG. 9. The input 67 to the LLFU is a set of 6 32-bit words and aDataValid bit, all generated by the HCU. The output 68 is a set of 90bits representing a maximum of 15 printhead segments of 6 colors. Notall the output bits may be valid, depending on how many colors areactually used in the printhead.

The physical placement of firing nozzles on the printhead referencedabove, nozzles in two offset rows, means that odd and even dots of thesame color are for two different lines. The even dots are for line L,and the odd dots are for line L-2. In addition, there is a number oflines between the dots of one color and the dots of another. Since the 6color planes for the same dot position are calculated at one time by theHCU, there is a need to delay the dot data for each of the color planesuntil the same dot is positioned under the appropriate color nozzle

The size of each buffer line depends on the width of the printhead.Since a single PEC generates dots for up to 15 printhead segments, asingle odd or even buffer line is therefore 15 sets of 640 dots, for atotal of 9600 bits (1200 bytes). For example, the buffers required forcolor 6 odd dots totals almost 45 KBytes.

The entire set of requisite buffers might be provided on the PEC chipwhen manufacturing techniques are capable. Otherwise, the buffers forcolors 2 onward may be stored in external DRAM. This enables the PEC tobe valid even though the distance between color planes may change in thefuture. It is trivial to keep the even dots for color 1 on PEC, sinceeverything is printed relative to that particular dot line (noadditional line buffers are needed). In addition, the 2 half-linesrequired for buffering color 1 odd dots saves substantial DRAMbandwidth. The various line buffers (on chip and in DRAM) need to bepre-loaded with all 0s before the page is printed so that it has cleanedges. The end of the page is generated automatically by the HCU so itwill have a clean edge.

In FIG. 10 is seen a block diagram for Color N OESplit (see Oesplit 70of FIG. 9), and the block diagram for each of the two buffers E and F,71,72 in FIG. 9 can be found in FIGS. 10 and 11. Buffer EF is a doublebuffered mechanism for transferring data to the printhead interface(PHI) 32 in FIG. 3. Buffers E and F therefore have identical structures.During the processing of a line of dots, one of the two buffers iswritten to while the other is being read from. The two buffers arelogically swapped upon receipt of the line-sync signal from the PHI.Both buffers E and F are composed of 6 sub-buffers, 1 sub-buffer percolor, as shown in FIG. 11, the color 1 sub-buffer numbered 73. The sizeof each sub-buffer is 2400 bytes, enough to hold 15 segments at 1280dots per segment. The memory is accessed 32-bits at a time, so there are600 addresses for each sub-buffer (requiring 10 bits of address). Allthe even dots are placed before the odd dots in each color's sub-buffer.If there is any unused space (for printing to fewer than 15 segments) itis located at the end of each color's sub-buffer. The amount of memoryactually used from each sub-buffer is directly related to the number ofsegments actually addressed by the PEC. For a 15 segment printhead thereare 1200 bytes of even dots followed by 1200 bytes of odd dots, with nounused space. The number of sub-buffers gainfully used is directlyrelated to the number of colors used in the printhead. The maximumnumber of colors supported is 6.

The addressing decoding circuitry for each of buffers E and F is suchthat in a given cycle, a single 32-bit access can be made to all 6sub-buffers—either a read from all 6 or a write to one of the 6. Onlyone bit of the 32-bits read from each color buffer is selected, for atotal of 6 output bits. The process is shown in FIG. 11. 15 bits ofaddress allow the reading of a particular bit by means of 10-bits ofaddress being used to select 32 bits, and 5-bits of address choose 1-bitfrom those 32. Since all color sub-buffers share this logic, a single15-bit address gives a total of 6 bits out, one bit per color. Eachsub-buffer 73 to 78 has its own WriteEnable line, to allow a single32-bit value to be written to a particular color buffer in a givencycle. The individual WriteEnables are generated by ANDing the singleWriteEnable input with the decoded form of ColorSelect. The 32-bits ofDataIn on line 79 are shared, since only one buffer will actually clockthe data in.

Address generation for reading from buffers E and F is straightforward.Each cycle generates a bit address that is used to fetch 6 bitsrepresenting 1-bit per color for a particular segment. By adding 640 tothe current bit address, we advance to the next segment's equivalentdot. We add 640 (not 1280) since the odd and even dots are separated inthe buffer. We do this NumSegments times to retrieve the datarepresenting the even dots, and transfer those bits to the PHI. WhenNumSegments=15, the number of bits is 90 (15×6 bits). The process isthen repeated for the odd dots. This entire even/odd bit generationprocess is repeated 640 times, incrementing the start address each time.Thus all dot values are transferred to the PHI in the order required bythe printhead in 640×2×NumSegments cycles. When NumSegments=15, thenumber of cycles is 19,200 cycles. Note that regardless of the number ofcolors actually used in the printhead, 6 bits are produced in a givenread cycle (one bit from each color's buffer).

In addition, we generate the TWriteEnable control signal for writing tothe 90-bit Transfer register 90 in FIG. 9. Since the LLFU starts beforethe PHI, we must transfer the first value before the Advance pulse fromthe PHI. We must also generate the next value in readiness for the firstAdvance pulse. The solution is to transfer the first value to theTransfer register after NumSegments cycles, and then to stallNumSegments cycles later, waiting for the Advance pulse to start thenext NumSegments cycle group. Once the first Advance pulse arrives, theLLFU is synchronized to the PHI.

The read process for a single dotline is shown in the followingpseudocode:

DoneFirst = FALSE WantToXfer = FALSE For DotInSegment0 = 0 to 1279 If(DotInSegment0:bit0 == 0) CurrAdr = DotInSegment0 (high bits) (puts inrange 0 to 639) EndIf XfersRemaining = NumSegments Do WantToXfer =(XfersRemaining == 0) TWriteEnable = (WantToXfer AND NOT DoneFirst) ORPHI: ADVANCE DoneFirst = DoneFirst OR TWriteEnable Stall = WantToXferAND (NOT TWriteEnable) SWriteEnable = NOT(Stall) If (SWriteEnable) ShiftRegister = Fetch 6 bits from EFSense[ReadBuffer]: CurrAdr CurrAdr =CurrAdr + 640 XfersRemaining = XfersRemaining − 1 EndIf Until(TWriteEnable) EndFor Wait until BufferEF Write process has finishedEFSense = NOT (EFSense)

While read process is transferring data from E or F to the PHI, a writeprocess is preparing the next dot-line in the other buffer.

The data being written to E or F is color 1 data generated by the HCU,and color 2–6 data from buffer D (supplied from DRAM). Color 1 data iswritten to EF whenever the HCU's OutputValid flag is set, and color 2–6data is written during other times from register C.

Buffer OE₁ 81 in FIG. 9 is a 32-bit register used to hold a singleHCU-generated set of contiguous 32 dots for color 1. While the dots arecontiguous on the page, the odd and even dots are printed at differenttimes.

Buffer AB 82 is a double buffered mechanism for delaying odd dot datafor color 1 by 2 dotlines. Buffers A and B therefore have identicalstructures. During the processing of a line of dots, one of the twobuffers is read from and then written to. The two buffers are logicallyswapped after the entire dot line has been processed. A single bit flagABSense determines which of the two buffers are read from and writtento.

The HCU provides 32-bits of color 1 data whenever the output validcontrol flag is set, which is every 32 cycles after the first flag hasbeen sent for the line. The 32 bits define a contiguous set of 32 dotsfor a single dot line—16 even dots (bits 0, 2, 4 etc.), and 16 odd dots(bits 1, 3, 5 etc.). The output valid control flag is used as aWriteEnable control for the OE₁ register 81. We process the HCU dataevery 2 OutputValid signals. The 16 even bits of HCU color 1 data arecombined with the 16 even bits of register OE₁ to make 32-bits of evencolor 1 data. Similarly, the 16 odd bits of HCU color 1 data arecombined with the 16 odd bits of register OE₁ to make 32-bits of oddcolor 1 data. Upon receipt of the first OutputValid signal of the groupof two, we read buffer AB to transfer the odd data to color 1, 73 inFIG. 11 within buffer EF. Upon receipt of the second OutputValid signalof the group of two, we write the 32-bits of odd data to the samelocation in buffer AB that we read from previously, and we write the32-bits of even data to color 1 within buffer EF.

The HCU provides 32 bits of data per color plane whenever theOutputValid control flag is set.

This occurs every 32 cycles except during certain startup times. The 32bits define a contiguous set of 32 dots for a single dot line—16 evendots (bits 0, 2, 4 etc.), and 16 odd dots (bits 1, 3, 5 etc.).

While buffer OE₁ (83 in FIG. 10) is used to store a single 32-bit valuefor color 1, buffers OE₂ to OE₆ are used to store a single 32-bit valuefor colors 2 to 6 respectively. Just as the data for color 1 is splitinto 32-bits representing color 1 odd dots and 32-bits representingcolor 1 even dots every 64 cycles (once every two OutputValid flags),the remaining color planes are also split into even and odd dots.

However, instead of being written directly to buffer EF, the dot data isdelayed by a number of lines, and is written out to DRAM via buffer CD(84 in FIG. 9). While the dots for a given line are written to DRAM, thedots for a previous line are read from DRAM and written to buffer EF(71,72). This process must be done interleaved with the process writingcolor 1 to buffer EF.

Every time an OutputValid flag is received from the HCU on line 85 inFIG. 10, the 32-bits of color N data are written to buffer OE_(N) (83).Every second OutputValid flag, the combined 64-bit value is written tocolor buffer N (86). This happens in parallel for all color planes 2–6.Color Buffer N (86) contains 40 sets of 64-bits (320 bytes) to enablethe dots for two complete segments to be stored. This allows a completesegment generation time (20×64=1280 cycles) for the previous segment'sdata (both odd and even dots) to be written out to DRAM. Addressgeneration for writing is straightforward. The ColorNWriteEnable signalon line 87 is given every second OutputValid flag. The address starts at0, and increments every second OutputValid flag until 39. Instead ofadvancing to 40, the address is reset to 0, thus providing thedouble-buffering scheme. This works so long as the reading does notoccur during the OutputValid flag, and that the previous segment's datacan be written to DRAM in the time it takes to generate a singlesegment's data. The process is shown in the following pseudocode:

adr = 0 firstEncountered = 0 While (NOT AdvanceLine) If(HCU_OutputValid) AND (firstEncountered)) ColorNWriteEnable = TRUEColorNAdr = adr If (adr == 39) adr = 0 Else adr = adr + 1 EndIf ElseColorNWriteEnable = FALSE EndIf If (HCU_OutputValid) firstEncountered =NOT(firstEncountered) EndIf EndWhile

Address generation for reading is trickier, since it is tied to thetiming for DRAM access (both reading and writing), buffer EF access, andtherefore color 1 generation. It is more fully explained below.

Address generation for buffers C, D, E, F, and colorN are all tied tothe timing of DRAM access, and must not interfere with color 1processing with regards to buffers E and F. The basic principle is thatthe data for a single segment of color N (either odd or even dots) istransferred from the DRAM to buffer EF via buffer CD. Once the data hasbeen read from DRAM those dots are replaced based on the values inColorBufferN. This is done for each of the colors in odd and even dots.After a complete segment's worth of dots has accumulated (20 sets of 64cycles), then the process begins again. Once the data for all segmentsin a given printline has been transferred from and to DRAM, the currentaddress for that color's DRAM buffer is advanced so that it will be theappropriate number of lines until the particular data for the color'sline is read back from DRAM. In this respect then, the DRAM acts as aform of FIFO. Consequently color N (either odd or even) is read fromDRAM into buffer D while copying color N (same odd/even sense) to bufferC. The copying of data to buffer C takes 20 or 21 cycles depending onwhether the OutputValid flag occurs during the 20 transfers. Once bothtasks have finished (typically the DRAM access will be the slower task),the second part of the process begins. The data in buffer C is writtento DRAM (the same locations as were just read) and the data in buffer Dis copied to buffer EF (again, no color N data is transferred to bufferEF while the OutputValid flag is set since color 1 data is beingtransferred). When both tasks have finished the same process occurs forthe other sense of color N (either odd or even), and then for each ofthe remaining colors. The entire double process happens 10 times. Theaddresses for each of the current lines in DRAM are then updated for thenext line's processing to begin.

In terms of bandwidth, the DRAM access for dot data buffers consumes thegreat majority of all DRAM access from PEC. For each print line we readan entire dot line for colors 2–6, and write an entire dot line forcolors 2–6. For the maximum of 15 segments this equates to 2×5×15×1280bits=192,000 bits (24,000 bytes) per print line. For the fastestprinting system (30,000 lines per second) this equates to 687 MB/sec.For 1 Page per second printing the bandwidth required is 312 MB/sec.Since the bandwidth is so high, the addresses of the various half-linesfor each color in DRAM should be optimized for the memory type beingused. In an RDRAM memory system for example, the very first half-linebuffer is aligned for each color to a 1 KByte boundary to maximizepage-hits on DRAM access. As the various segments are processed it isnecessary to ensure that if the start of the next segment was going tobe aligned at byte 960 within the 1 KByte page, then the 640-bit accesswould span 2 pages. Therefore the variable DRAMMaxVal is used to checkfor this case, and if it occurs, the address is rounded up for the nexthalf-line buffer to be page-aligned. Consequently the only waste is 64bytes per 13 segments, but have the advantage of the 640-bit accesscompletely within a single page.

The address generation process can be considered as NumSegments worth of10 sets of: 20×32-bit reads followed by 20×32-bit writes, and it can beseen in the following pseudocode:

EFStartAdr = 0 Do NumSegments times: For CurrColor = 0 to MaxHalfColorsDRAMStartAddress = ColorCurrAdr[CurrColor] While reading 640 bits fromDRAMStartAddress into D(>= 20 cycles) ColorNAdr = 0 While (ColorNAdr !=20) If (NOT HCU_OutputValid) TransferColorNBuffer[ColorNAdr|CurrColor_bit0] to C[ColorNAdr] ColorNAdr =ColorNAdr + 1 EndIf EndWhile EndWhile - wait until read has finishedWhile writing 640 bits from C into DRAMStartAddress (>=20 cycles)ColorNAdr = 0 EFAdr = EFStartAdr While (ColorNAdr != 20) If (NOTHCU_OutputValid) Transfer D[ColorNAdr] to EF[CurrColor|EFAdr] If((ColorNAdr == 19) AND (CurrColor == NumHalfColors)) EFStartAdr =EFAdr + 1 Else EFAdr = EFAdr + 1 EndIf ColorNAdr = ColorNAdr + 1 EndIfEndWhile EndWhile - wait until write has finished If (DRAMStartAddress== DRAMMaxVal) ColorCurrAdr[currColor] = round up DRAMStartAddress tonext 1KByte page Else ColorCurrAdr[currColor] = DRAMStartAddress + 640bits EndIf If (Segment == maxSegments) If (ColorCurrRow[CurrColor] ==ColorMaxRow[CurrColor]) ColorCurrRow[currColor] =ColorStartRow[currColor] ColorCurrAdr[currColor] =ColorStartAdr[currColor] Else ColorStartRow[currColor] =ColorCurrRow[currColor] + 1 EndIf EndIf EndFor EndDo Wait until nextAdvance signal from PHI

Note that the MaxHalfColors register is one less than the number ofcolors in terms of odd and even colors treated separately, but notincluding color 1. For example, in terms of a standard 6 color printingsystem there are 10 (colors 2–6 in odd and even), and so MaxHalfColorsshould be set to 9.

The LLFU requires 2NumSegments cycles to prepare the first 180 bits ofdata for the printhead interface (PHI) 32. Consequently the printheadshould be started and the first LineSync pulse must occur this period oftime after the LLFU has started. This allows the initial Transfer valueto be valid and the next 90-bit value to be ready to be loaded into theTransfer register.

The printhead interface (PHI) 32 is the means by which the processorloads the printhead with the dots to be printed, and controls the actualdot printing process. It takes input from the LLFU and outputs data tothe printhead itself The PHI is capable of dealing with a variety ofprinthead lengths and formats. In terms of broad operatingcustomizations, the PHI is parameterized according to Table 33:

TABLE 33 Basic printing parameters Name Description Range MaxColors Noof Colors in printhead 1–6 SegmentsPerXfer No of segments written to pertransfer. Is equal to the number 1–8 of segments in the largest segmentgroup SegmentGroups No of segment groups in printhead 1–2

The internal structure of the PHI allows for a maximum of 6 colors, 8segments per transfer, and a maximum of 2 segment groups. This issufficient for a 15 segment (8.5 inch) printer capable of printingA4/Letter at full bleed. Multiple PECs can be connected together toproduce wider prints as necessary.

The printhead interface (PHI) contains:

-   -   a LineSyncGen unit (LSGU), which provides synchronization        signals for multiple PEC chips (allows side-by-side printing and        front/back printing) as well as stepper motors.    -   a Memjet interface (MJI), which transfers data to the Memjet        printhead.

In FIG. 12 is seen the internal structure of the printhead interface(PHI) 32. In the PHI there are two LSGUs 89,90. The first LSGU 90produces LineSync0 (LS0), which is used to control the Memjet Interface(MJI) in all synchronized chips. The second LSGU 89 produces LineSync1(LS1) which is used to pulse the paper drive stepper motor.

A Master/Slave pin on the chip at 91 allows multiple chips to beconnected together for side-by-side printing, front/back printing etc.via a Master/Slave relationship. When the Master/Slave pin is attachedto VDD, the chip is considered to be the Master, and LineSync pulsesgenerated by the LineSyncGen unit 90 is enabled onto the two tri-stateLineSync common line LineSync0, shared by all the chips via twotri-state enables 92. When the Master/Slave pin is attached to GND, thechip is considered to be the Slave, and LineSync pulses generated by thetwo LineSyncGen units 89,90 are not enabled onto the common LineSynclines. In this way, the Master chip's LineSync pulses are used by allPHIs on all the connected chips. The LineSyncGen units (LSGU) 89,90 areresponsible for generating the synchronization pulses required forprinting a page. Each LSGU produces an external LineSync signal toenable line synchronization. A generator inside the LGSU generates aLineSync pulse when told to ‘go’, and then every so many cycles untiltold to stop. The LineSync pulse defines the start of the next line. Theexact number of cycles between LineSync pulses is determined by theCyclesBetween-Pulses register, one per generator. It must be at leastlong enough to allow one line to print and another line to load, but canbe longer as desired (for example, to accommodate special requirementsof paper transport circuitry). If the CyclesBetweenPulses register isset to a number less than a line print time, the page will not printproperly since each LineSync pulse will arrive before the particularline has finished printing.

The following interface registers are contained in the LSGU:

TABLE 34 LineSyncGen Unit registers Register Name DescriptionCyclesBetweenPulses The number of cycles to wait between generating oneLineSync pulse and the next. Go Controls whether the LSGU is currentlygenerating LineSync pulses or not. A write of 1 to this registergenerates a LineSync pulse, transfers CyclesBetweenPulses toCyclesRemaining, and starts the countdown. When CyclesRemaining hits 0,another LineSync pulse is generated, CyclesBetweenPulses is transferredto CyclesRemaining and the countdown is started again. A write of 0 tothis register stops the countdown and no more LineSync pulses aregenerated. CyclesRemaining A status register containing the number ofcycles remaining until the next LineSync pulse is generated.

The LineSync pulse is not used directly from the LGSU. The LineSync0pulse is enabled onto a tri-state LineSync0 line 97 only if theMaster/Slave pin at 91 is set to Master. Consequently the LineSync pulseis only used in the form as generated by the Master PEC (pulsesgenerated by Slave PECs are ignored).

The Memjet interface (MJI) 93 transfers data to the Memjet printhead at94, and tells the Memjet interface when to start printing the next lineof data. It is also used to enable feedback from a specified segment.The Memjet printhead 95 itself is responsible for controlling the firingsequence of its nozzles, with firing profiles programmed via the I²Cserial interface 36 in FIG. 3. The MJI contains a state machine thatfollows the printhead loading order described in Section 18.1, and itmay include functionality for a preheat cycle and a cleaning cycle. Dotcounts for each color are also kept by the MJI (see below).

The MJI loads data into the printhead from a choice of 2 data sources:

All 1s. This means that all nozzles will fire during a subsequent Printcycle, and is the standard mechanism for loading the printhead for apreheat or cleaning cycle.

From the 90-bit input held in the Transfer register of the LLFU. This isthe standard means of printing an image. In a first transfer, the first48 bits are sent to the printhead, and in a second transfer, the last 42bits are sent to the printhead with the top 6 bits 0. Once all 90 bitshave been sent, a 1-bit ‘Advance’ control pulse is sent to the LLFU.

The MJI knows how many lines it has to print for the page. When the MJIis told to ‘go’, it waits for a LineSync pulse before it starts thefirst line (via an NPSync pulse to the printhead). Once it has finishedloading/printing a line, it waits until the next LineSync pulse beforestarting the next line. The MJI stops once the specified number of lineshas been loaded/printed, and ignores any further LineSync pulses. TheMJI is therefore directly connected to the LLFU 31 (see FIGS. 3 and 4)at 96, LineSync0 at 97 (shared between all synchronized chips), and theexternal Memjet printhead 95. The MJI accepts 90 bits of data from theLLFU. Of these 90 bits, only the bits corresponding to the number ofsegments and number of colors will be valid. The MJI's state machinedoes not care which bits are valid and which bits are not valid—itmerely passes the bits out to the printhead. The data lines and controlsignals coming out of the MJI are wired to the pinouts of the chip asdescribed below.

The MJI has a number of connections to the printhead, including amaximum of 6 colors, clocked in to a maximum of 8 segments per transferto a maximum of 2 segment groups. Table 35 lists the connections, withthe sense of input and output with respect to the MJI. The namescorrespond to the pin connections on the printhead.

TABLE 35 Memjet Interface Connections Name # Pins I/O DescriptionD1[0–7] 8 O Output to D1 shift register of segments 0–7 D2[0–7] 8 OOutput to D1 shift register of segments 0–7 D3[0–7] 8 O Output to D3shift register of segments 0–7 D4[0–7] 8 O Output to D4 shift registerof segments 0–7 D5[0–7] 8 O Output to D5 shift register of segments 0–7D6[0–7] 8 O Output to D6 shift register of segments 0–7 SCIk[1–2] 2 O Apulse on SCIK[N] (ShiftRegisterClock) loads the current values fromD1[0–7], D2[0–7], D3[0–7], D4[0–7], D5[0–7] and D6[0–7] into the segmentgroup N on the printhead. Ten 1 O Parallel transfer of data from theshift registers to the printhead's internal NozzleEnable bits. CCEn[1–2]2 O A pulse on CCEn[N] ANDed with data on D1[n] enables the sense linesfor segment n in segment group N of the printhead PHSense 1 I PrintheadSense (temperature, voltage, resistivity etc) Reset 1 O Reset theprinthead TOTAL 55

The MJI maintains a count of the number of dots of each color fired fromthe printhead. The dot count for each color is a 32-bit value,individually cleared under processor control. At 32-bits length, eachdot count can hold a maximum coverage dot count of 17 8-inch×12-inchpages, although in typical usage, the dot count will be read and clearedafter each page or half-page. The dot counts are used by the processorto update a QA chip in order to predict when the ink cartridge runs outof ink. The processor knows the volume of ink in the cartridge for eachof the colors from the QA chip. Counting the number of drops eliminatesthe need for ink sensors, and prevents the ink channels from runningdry. An updated drop count is written to the QA chip after each page. Anew page will not be printed unless there is enough ink left, and allowsthe user to change the ink without getting a dud half-printed page whichmust be reprinted.

In FIG. 13 is seen the layout of a dot counter for Color N. All 6 dotcounters are preferably identical in structure. The dot counter takesthe color N data at 98, from the HCU, into a 15 line to 4 line encoder99. The four line output of the encoder 99 is to an adder 100 and ColorN Dot Count 101 outputting a 32 bit count at 102. The counter 101 mightbe cleared by a bit on line 103. Loading of the counter 101 is clockedby a bit on 104.

The processor communicates with the MJI via a register set. Theregisters allow the processor to parameterize a print as well as receivefeedback about print progress. The following registers are contained inthe MJI:

TABLE 36 Memjet interface registers Register Name Description PrintParameters SegmentsPerXfer The number of segments to write to eachtransfer. This also equals the number of cycles to wait between eachtransfer (before generating the next Advance pulse). Each transfer hasMaxColors × SegmentsPerXfer valid bits. SegmentGroups The number ofsegment groups in the printhead. This equals the number of times thatSegmentsPerXfer cycles must elapse before a single dot has been writtento each segment of the printhead. The MJI does this 1280 times tocompletely transfer all the data for the line to the printhead. NumLinesThe number of Load/Print cycles to perform. Monitoring the Print (readonly from point of view of processor) Status The Memjet Interface'sStatus Register LinesRemaining The number of lines remaining to beprinted. Only valid while Go = 1. Starting value is NumLines and countsdown to 0. TransfersRemaining The number of sets of SegmentGroupstransfers remaining before the Printhead is considered loaded for thecurrent line. Starts at 1280 and counts down to 0. only valid while Go= 1. SegGroupsRemaining The number of segment groups remaining in thecurrent set of transfers of 1 dot to each segment. Starts atSegmentGroups and counts down to 0. Only valid while Go = 1.SenseSegment The 8-bit value to place on the D1 lines during asubsequent feedback CCEn pulse. Only 1 of the 8 bits should be set,corresponding to one of the (maximum) 8 segments. See SenseSelect forhow to determine which of the segment groups to sense. SetAllNozzles Ifnon-zero, the 48-bit value written to the printhead during the LoadDotsprocess is all 1s, so that all nozzles will be fired during thesubsequent PrintDots process. This is used during the preheat andcleaning cycles. If 0, the 48-bit value written to the printhead comesfrom the LLFU. This is the case during the actual printing of regularimages. Actions Reset A write to this register resets the MJI, stops anyloading or printing processes, and- loads all registers with 0. The MJIalso places a pulse on the RESET line connected to the printhead.SenseSelect A write to this register with any value clears theFeedbackValid bit of the Status register, and the remaining actiondepends on the values in the LoadingDots and PrintingDots status bits.If either of the status bits are set, the Feedback bit is cleared andnothing more is done. If both status bits are clear, a pulse is givensimultaneously on both CCEn lines with all Dn bits 0. This stops anyexisting feedback. Depending on the two low-order bits written toSenseSelect register, a pulse is given on CCEn1 or CCEn2, with the D1bits set according to the SenseSegment register. Once the sense line hasbeen tested, the value is placed in the PHSense registers, and theFeedback bit of the Status register is set. Go A write of 1 to this bitstarts the LoadDots / PrintDots cycles, which commences with a wait forthe first LineSync pulse. A total of NumLines lines are printed, eachline being loaded/printed after the receipt of a LineSync pulse. Theloading of each line consists of SegmentGroups 48-bit transfers. As eachline is printed, LinesRemaining decrements, and TransfersRemaining isreloaded with SegmentGroups again, and an NPSync pulse is given to theprinthead. The status register contains print status information. Uponcompletion of NumLines, the loading/printing process stops, the Go bitis cleared, and any further LineSync pulses are ignored. During thefinal print cycle, nothing is loaded into the printhead. A write of 0 tothis bit stops the print process, but does not clear any otherregisters. ClearCounts A write to this register clears theColor1DotCount, Color2DotCount, Color3DotCount, Color4DotCount,Color5DotCount, and Color6DotCount registers if bits 0, 1, 2, 3, 4, 5,or 6 respectively are set. Consequently a write of 0 has no effect.Feedback PHSense Read only feedback of the printhead's sense from thelast CCEn pulse sent to segment SenseSegment. Is only valid if theFeedbackValid bit of the Status register is set. Color1DotCount Readonly 32-bit count of color1 dots sent to the printhead. Color2DotCountRead only 32-bit count of color2 dots sent to the printhead.Color3DotCount Read only 32-bit count of color3 dots sent to theprinthead Color4DotCount Read only 32-bit count of color4 dots sent tothe printhead Color5DotCount Read only 32-bit count of color5 dots sentto the printhead Color6DotCount Read only 32-bit count of color6 dotssent to the printhead

The MJI's Status register is a 16-bit register with bit interpretationsas follows:

TABLE 37 MJI Status register Name Bits Description LoadingDots 1 If set,the MJI is currently loading dots, with the number of dots remaining tobe transferred in TransfersRemaining. If clear, the MJI is not currentlyloading dots PrintingDots 1 If set, the MJI is currently printing dots.If clear, the MJI is not currently printing dots. FeedbackValid 1 Thisbit is set while the feedback values Tsense, Vsense, Rsense, and Wsenseare valid. Reserved 13 —

The following pseudocode illustrates the logic required to load aprinthead for a single line. Note that loading commences only after theLineSync pulse arrives. This is to ensure the data for the line has beenprepared by the LLFU and is valid for the first transfer to theprinthead.

Wait for LineSync For TransfersRemaining = 1280 to 0 For I = 0 toSegmentGroups If (SetAllNozzles) Set all Dn lines to be 1 Else If (I =0) Place first 48 bits of LLFU's 90 bit Transfer register on 48 Dn linesElse Place last 42 bits of LLFU's 90 bit Transfer register on 48 Dnlines EndIf Pulse SClk Wait SegmentsPerXfer cycles Send ADVANCE signalEndFor EndFor

Cleaning and preheat cycles are simply accomplished by settingappropriate registers in the MJI and programming the printhead's firingpulse profiles.

-   SetAllNozzles=1-   Set the firing pulse profile to either a low duration (in the case    of the preheat mode) or to an appropriate drop ejection duration for    cleaning mode.-   Set NumLines to be the number of times the nozzles should be fired-   Set the Go bit and then wait for the Go bit to be cleared when the    print cycles have completed.

The LSGU must also be programmed to send LineSync pulses at the correctfrequency.

Throughout the specification the aim has been to describe the preferredembodiments of the invention without limiting the invention to any oneembodiment or specific collection of features. Persons skilled in theart may realize variations from the specific embodiments that willnonetheless fall within the scope of the invention.

1. A printer with a multi-segment printhead, having a plurality ofsynchronised engine/controller chips, each chip configurable to becoupled with other engine/controller chips to drive the multi-segmentprinthead comprising: a memory buffer for receiving compressed pagedata; image decoders for expanding the compressed page data; ahalf-toner/compositor to composite respective strips of the decodedimage planes to produce composite strips; and a printhead interface tooutput the composite strip to a printhead the printhead interfaceincluding: two output units, a first output unit providing asynchronization signal for multiple print engine/controller chips and asecond output unit adapted to pulse a paper drive stepping motor, eachoutput unit producing an external signal to enable line synchronization,a generator in each output unit producing a pulse in a number of cyclesuntil instructed to stop, the pulse defining a start of a next line. 2.The printer of claim 1 wherein: the printhead interface is adapted toreceive an input signal which determines if the print engine controlleris a master controller or a slave.
 3. The printer of claim 1 wherein:number of cycles is determined by a register, each cycle being longenough to allow a line to print and another line to load.
 4. The printerof claim 1, wherein: the half-toner/compositor has as an input, anexpanded contone layer, an expanded bi-level spot layer, an expandeddither-matrix-select bitmap and tag data; the halftoner/compositorfurther comprising an output interface for transferring data to theprinthead and enabling feedback from a specific segment.
 5. The printerof claim 4 wherein: the output interface contains a state machine thatfollows the printhead loading order and a dot count for each color. 6.The printer of claim 4 wherein: the output interface is directlyconnected to a line loader/format unit and the printhead.
 7. The printerof claim 4 wherein: the output interface loads data into the printheadfrom a first data source which is all binary ones causing a firing ofall nozzles of the printhead during a subsequent print cycle; and theoutput interface loads data into the printhead from a second data sourcebeing an input held in a transfer register of a line loader/format unit.8. The printer of claim 4 wherein: the output interface has a number ofconnections to the printhead, comprising a number of color connectionsclocked into a second number of segments per transfer to one or twosegment groups.
 9. The printer of claim 4 wherein: the output interfacemaintains a count of the number of dots of each color fired from theprinthead, the count being a value which is independently cleared underprocessor control.
 10. The printer of claim 9 wherein: a dot count isused by a processor on the chip to update a QA chip in order to predictwhen an ink cartridge runs out of ink.
 11. The printer of claim 10wherein: the processor communicated with the output interface via aregister set that allows the processor to parameterize a print as wellas receive feedback about a print.
 12. The printer of claim 10 wherein;an updated dot count is written to the QA chip after a page iscompleted.
 13. The printer of claim 1 wherein: the expansion furthercomprises, in parallel with the layers, of a Group 4 Fax-compressedbi-level dither matrix selection map.
 14. The printer of claim 13wherein: the expansion further comprises a second stage dithering of thecontone CMYK layer using a dither matrix selected by the dither matrixselect map.
 15. The printer of claim 1, wherein: thehalf-toner/compositor further comprises a number of scale units, eachscale unit receiving data from a buffer layer and at least one scaleunit receiving two control bits, the control bits being an advance dotbit and an advance line bit.
 16. The printer of claim 15, wherein: theadvance dot bit allows for the generation of multiple instances ofidentical dot data and the advance line bit provides for truncation ofdata according to a printer margin.
 17. The printer of claim 15,wherein: the buffer layer comprise contone layers, a bi-level spot layerand a dither select matrix layer, each of which may be scaledindependently.